Packaged banded envelopes

ABSTRACT

An arrangement of envelope packages, the arrangement including a plurality of discreet envelope packages, each package including a plurality of generally aligned envelopes which are compressed together. The plurality of envelope packages are arranged in a first row and a second row located above the first row in a vertical direction thereof. At least one envelope package of the first row is oriented generally perpendicular to at least one envelope package of the second row.

This application is a continuation of U.S. patent application Ser. No.11/378,994, filed on Mar. 17, 2006, which is continuation-in-part ofU.S. patent application Ser. No. 11/224,475 filed on Sep. 12, 2005 (nowU.S. Pat. No. 7,310,922), which in turn claims priority to provisionalapplication Ser. No. 60/609,293 filed on Sep. 13, 2004, and provisionalapplication Ser. No. 60/616,171 filed on Oct. 5, 2004. The entirecontents of all these applications are hereby incorporated by reference.

The present invention is directed to packaging of banded envelopes andmethods for packaging banded envelopes.

BACKGROUND

Existing envelope manufacturing machinery can create large numbers ofenvelopes at a rapid rate. Such machinery creates stacks of envelopesfor subsequent packaging, shipping and processing. The envelopes arethen shipped to a customer or end user which may add inserts into theenvelopes, affix postage, and enter the envelopes into a mail or packagedelivery system. The envelope inserting and processing is typicallycarried out by automated envelope inserting machinery.

In order to ensure proper operation of the envelope inserting machinery,the envelopes processed by the machinery should be uniform and meetsufficient quality control standards. In particular, after theirformation envelopes may be prone to absorbing moisture from the ambientair, which causes warping of the envelopes. The absorption of moistureand warping of the envelope over time is known as “propellering.”Propellering of the envelopes can cause the opposing corners of theenvelopes to twist away from each other in the fashion of a propeller,which can cause the envelopes to be improperly fed into and/orimproperly processed by the envelope inserting machinery. This can leadto jamming or malfunction of the envelope inserting machinery, whichincreases down time and lowers efficiency.

Most of the moisture absorbed by the envelopes takes place afterformation and packaging of the envelopes, while the envelopes are instorage, being shipped, or awaiting insertion. Accordingly, as disclosedherein envelopes may be packaged together in a compressed state toreduce moisture, reduce warpage and ensure consistently flat envelopes.

In addition, difficulties can arise in stacking and storing theindividual envelope packages. Accordingly there is a need for animproved system and method for packaging, storing and transportingpackages of banded envelopes.

SUMMARY

In one embodiment, the present invention is an arrangement of envelopepackages, the arrangement including a plurality of discreet envelopepackages, each package including a plurality of generally alignedenvelopes which are compressed together. The plurality of envelopepackages are arranged in a first row and a second row located above thefirst row in a vertical direction thereof. At least one envelope packageof the first row is oriented generally perpendicular to at least oneenvelope package of the second row.

In another embodiment the present invention is an envelope packagingarrangement including a storage container, an envelope stack including aplurality of envelopes located in the storage container, and aninflatable and deflatable bladder component located in the storagecontainer. The bladder component compresses the plurality of envelopesof the envelope stack together to improve the shipping characteristicsof the envelope stack.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a front view of an unassembled envelope;

FIG. 1B is a front view of the envelope of FIG. 1A, shown in anassembled state;

FIG. 2A is a top perspective view of a packaging box including aplurality of envelopes received therein;

FIG. 2B is a top perspective view of a shipping box including aplurality of the packaging boxes of FIG. 2A received therein;

FIG. 3A is a front perspective view of a package of banded envelopes;

FIG. 3B is a rear perspective view of the package of FIG. 3A;

FIG. 3C is a top view of the package of FIG. 3A;

FIG. 3D is a front perspective view of an envelope dispenser;

FIG. 3E is a front perspective view of the envelope dispenser of FIG. 3Dreceiving four envelope packages therein;

FIG. 4 is a stack of a plurality of envelope packages;

FIG. 5 is a front perspective view of another embodiment of the packageof envelopes of the present invention;

FIG. 6 is a top schematic view of a packaging method of the presentinvention;

FIGS. 7-25 are a series of front perspective schematic viewsillustrating a method for forming a package of banded envelopes of thepresent invention;

FIGS. 26-33 are a series of front perspective schematic viewsillustrating a method for loading packaged envelopes into an envelopeinserting machine;

FIGS. 34-48 are a series of front perspective schematic viewsillustrating a partially automated method for loading packaged envelopesinto a plurality of envelope inserting machines;

FIGS. 49-64 are a series of front perspective schematic viewsillustrating a fully automated method for loading packaged envelopesinto a plurality of envelope inserting machines;

FIG. 65 is a top perspective view of a tray with a plurality of packagesof banded envelopes stacked therein; and

FIG. 66 is a top perspective view of a tray with a plurality of packagesof banded envelopes stacked therein in a different manner than that ofFIG. 65.

DETAILED DESCRIPTION

FIGS. 1A and 1B illustrate a envelope 10 in its unassembled andassembled conditions, respectively. FIGS. 1A and 1B illustrate andiamond or diagonal cut envelope, but the invention can be implementedand used with envelopes of nearly any shape or configuration. Theenvelope 10 of FIGS. 1A and 1B includes a pair of side flaps 12, abottom flap 14, a top flap 16, and a central portion 18. The side flaps12, bottom flap 14 and top flap 16 are each foldable on top of thecentral portion 18 and can be adhered together to provide the envelope10 shown in FIG. 1B. The top flap 16 is pivotable to an open position toprovide access to the inner cavity of the envelope 10, and includes anadhesive strip (not shown) to seal the envelope 10 in the well-knownmanner. In the illustrated embodiment, the envelope 10 includes a pairof front windows 20 made of transparent, sheet-like material at theaddressee location and at the addressor location of the envelope 10.However, the envelope 10 may include only a single window (at either theaddressee or addressor location), or may not include any windows. Inaddition, the envelope 10 can take a wide variety of shapes andconfigurations beyond that specifically shown in FIGS. 1A and 1B.

FIGS. 2A and 2B illustrate a system for storing and shipping envelopes.In that system, a packaging box 22 having a removable lid 24 receives aloose stack of envelopes 10 therein (FIG. 2A). The envelopes 10 can beinserted into the packaging box 22 either manually or by an automatedprocess. The lid 24 is then fitted on the packaging box 22, and a numberof packaging boxes 22 (i.e., five packaging boxes 22) are inserted intoa shipping box 26 as shown in FIG. 2B. Various other methods for storingand shipping envelopes may be used, such as placing two stacks or row ofenvelopes in a side-by-side configuration into a shipping case, with adivider between the stacks/rows. However, these methods of storing andshipping envelopes do not prevent the absorption of moisture by theenvelopes, and present various other difficulties in shipping andhandling.

FIGS. 3A, 3B and 3C illustrate a package or stack 30 of banded envelopes10. The stack of envelopes 30 includes a plurality of envelopes 10 thatare generally aligned (i.e. their outer edges are generally aligned).The stack of envelopes 30 includes pair of bands 32 extending around theouter periphery of the stack 30. The bands 32 may be located on theouter longitudinal edges of each envelope 10 and each band 32 may bespaced apart from the associated adjacent lateral edge by the samedistance. The bands 32 may extend only around the longitudinal edges ofthe inner envelopes 10 (as well as the front and rear surfaces of theend envelopes 10 a, 10 b, respectively) such that all of the innerenvelopes in the stack 30 include two free (unbound) lateral edges.

FIG. 3B illustrates the envelopes 10 in a “flaps-up” configurationwherein the top flap 16 is located adjacent to, or forms, the upper edgeof the envelope 10. However, if desired the envelopes can be located ina “flaps-down” configuration wherein the envelopes 10 are inverted fromtheir configuration shown in FIG. 3B.

The bands 32 can be made of a wide variety of materials, including, butnot limited to, paper, coated paper, plastic, cardboard, ribbonmaterial, wire, rubber bands or other elastic material, non-elastic orgenerally non-elastic materials, MYLAR® film sold by E.I. DuPont deNemours and Company of Wilmington, Del., or any combination of thesematerials. The bands 32 may be made of a relatively thin, flexiblecontinuous material, such as material having a thickness between about0.05 mm and about 0.5 mm.

The bands 32 retain the stack of envelopes 30 in a compressed condition.Adjacent envelopes 10 in the stack 30 have a gap therebetween, and thegaps will typically be reduced due to the compressed nature of the stack30. The stack of envelopes 30 may be compressed such that the stack 30exerts an expansion force of at least about ½ pound, or at least abouttwo pounds, or at least about five pounds, or at least about ten pounds.Thus, the bands 32 should be able to withstand an expansion forceapplied by the stack of envelopes 30 of at least about ½ pound, or atleast about two pounds, or at least about five pounds, or at least aboutten pounds. In addition, each stack of envelopes 30 should besufficiently compressed to generally seal air and moisture out away fromthe innermost envelopes 10 in the stack 30. For example, the stack ofenvelopes 30 may be compressed at least about 1 inch, or about 10%, orat least about 20%, or at least about 30%, or at least about 50% fromits uncompressed state (i.e., a state wherein each of the envelopes 30touches any adjacent envelopes 10 but no external compressive forces areapplied).

Although greater compression may, in general, provide greater sealingbetween adjacent envelopes 10 and thereby keep air and moisture awayfrom the envelopes 10, over-compression of the envelopes 10 can lead toexcessive bowing in the stack. In particular, the center portions 15 ofeach envelope 10 have a four-ply or five-ply thickness due to theoverlapping nature of the five panels 12, 14, 16, 18 at that location.The remaining portions of the envelope 10 include only two-ply orthree-ply thicknesses. Accordingly, if the bands 32 are too tight andthe envelopes 10 are over-compressed, the outer edges of the envelopes10 will be pulled inwardly and the entire stack of envelopes 30 will bowabout the center portion 15 of the envelopes 10. This bowing can impartan undesired curvature to the envelopes 10 and therefore should belimited. Thus the stack of envelopes 30 should form a generallyrectangular prism. For example, the stack of envelopes 30 may beconfigured such that each envelope 10 in the stack is bowed (i.e.,pulled out of plane) by a distance of no greater than about ⅜″, or nogreater than about one quarter inch, or no greater than aboutone-fortieth of the length of the envelope 10.

Besides the compression advantages provided by the bands 32, the bands32 also provide advantages with respect to packaging and/or handling ofthe envelopes 10. For example, each band 32 may provide a flat surfaceupon which suction cups or other suction devices may be able to act tothereby grip, lift and manipulate the stack of envelopes 30. Thus, eachband 32 may have a width of at least, for example, about ¼″, or aboutone inch, or at least about one-tenth of the length of the envelope 10,to provide sufficient surface area upon which suction cups can act.Thus, the bands 32 may be of a generally airtight (or generally non-airpermeable) material that allows suction cups to seal thereto. Of course,various other methods of lifting and moving the envelopes may beutilized.

The bands 32 may be printed with various markings located thereon (seemarking 31 of FIGS. 3A and 3B). For example, various marks, indicia,targets, text, bar codes, computer or human readable information, or thelike which can be identified or tracked by optical equipment associatedwith a robot or the like (collectively termed “marking” or “markings”herein) may be printed on the bands 32. This markings 31 can be utilizedby a vision-guided robot in an envelope inserting/stuffing machine. Themarkings 31 can be a mark located a predetermined distance from the endsof the stack 30 (i.e., a predetermined distance from the front envelope10 a and/or rear envelope 10 b, or from the sides of the stack 30) sothat the optical equipment can determine the location of the outer edgesof the package 30. The bands 32 may also include markings 31 useful to ahuman operator, for example, an arrow indicating the orientation and/orfront end of the stack 30 for insertion into envelope inserting orprocessing equipment.

Each package 30 may include any of a desired number of envelopes. In oneembodiment each package 30 has between about 50 and about 1,000envelopes, and in one embodiment has about 250 envelopes. Each packageof envelopes 30 may have a depth of between about 1 inch to about 12inches, and more particularly about 6 inches.

The banded nature of the envelopes 10 allows the envelopes 10 to bestacked and handled in an improved manner as compared to nonbandedenvelopes. For example, as shown in FIG. 4, a stack 42 of packaged,banded envelopes 30 can be created on a flat surface, in a box or thelike. When the stack 42 shown in FIG. 4 is located in a box or on thefloor, each of the packages 30, including the topmost package ofenvelopes 30 a can support themselves as freestanding units. If theenvelopes 10 of the stack 30 a were not banded, the envelopes 10 of thatpackage 30 a would not be able to be freestanding, and would fallforward and/or backward and be difficult to contain.

Accordingly the banded nature of the packages 30 allows a user toextract a limited number of envelopes 10 for processing by simplygripping and lifting a package 30 off of the stack 42 of packages 30shown in FIG. 4 without causing the tumbling of loose envelopes. Thusthe packages 30 need not be bound on all sides by a container, andquicker and easier access to the packages 30 is provided. In addition,handling equipment (such as lifting slats or arms) can be insertedbetween the bands 32 and stack of envelopes 30 to lift, move andmanipulate the stack of envelopes 30.

Finally, because the packages of envelopes 30 are compression-bound, apile or stack 42 of packages 30 as shown in FIG. 4 can be created andstacked relatively high. In particular, the compression-bound nature ofthe envelopes lends stiffness to the packages 30 (i.e., in the verticaldirection) and allows multiple packages 30 to be piled or stacked on topof each other in a secure and stable manner. This allows greaterstacking efficiency and reduces freight costs and warehouse space.

As shown in FIG. 3D, an envelope dispenser 35 may be provided for usewith the envelope packages 30. The envelope dispenser 35 may have alower support panel 37, an upstanding back panel 39 oriented generallyperpendicular to the support panel 37, and a pair of opposed, upstandingside panels 41. Each side panel 41 has an opening 43 through which auser can extend his or her hands to grip and carry the envelopedispenser 35.

As shown in FIG. 3E the envelope dispenser 35 is configured to store apredetermined number of envelope packages 30 (four packages 30 in theillustrated embodiment). In this manner the envelope dispenser 35 can beutilized to transport multiple envelope packages 30. The envelopedispenser 35 may also be configured to dispense envelopes directly to anenvelope feeder during the manufacturing process. In particular, four(or more or less) envelope packages 30 could be located on the envelopedispenser 35. The bands 32 on the packages 30 could then be cut andremoved. An operator could then invert the dispenser 35 on top of aconveyer belt to thereby deposit the envelopes in an aligned and orderlymanner for easy processing. The use of the dispenser 35 in this mannerreduces repetitious movements by the operator and increases efficiency.

As shown in FIG. 5, rather than providing a pair of straps 32 locatedadjacent to the outer edges of the envelope stack 30, a single strap 32may be provided and located, for example, about the center 15 of theenvelopes 10 of the envelope stack 30. The use of a center strap 32 mayprevent over-compression of the stack of envelopes 30 due to theincreased thickness at the center portion 15 of the envelopes 10, asdiscussed above. However, the center strap 32 may, in certain cases, notprovide sufficient compression of the envelopes 30 due to the increasedthickness at the center of the envelopes 10 which limits compression.Thus, the use of straps 32 which are not located at the center of theenvelopes may be desired. The center strap 32 of FIG. 5 may be used incombination with one or both of the outer straps 32 of the arrangementof FIGS. 3A and 3B. Indeed, any of a variety and number of combinationsof straps may be utilized without departing from the scope of thepresent invention.

FIGS. 7-25 (as well as FIG. 6) illustrate a series of steps which may beutilized to form the stack of banded envelopes 30 shown in, for example,FIGS. 3A and 3B. However, it should be understood that the methodillustrated in FIGS. 7-25 is illustrative of only a single manner inwhich the banded envelopes 30 may be assembled, and various otherassembly method or steps may be utilized to assemble or create thebanded envelopes 30 of the present invention.

As shown in FIG. 7, the banded envelopes may be compiled and bandedusing a mechanized assembly, apparatus or envelope stacking machine 48.In the illustrated embodiment, the envelope stacking machine 48 includesa set of three co-axial spiral wheels or discs or delivery spiders 50located at the end of a support table or support surface 52. The table52 has a pair of slots 54 formed therein and extending the length of thetable 52. More or less slots 54 may be provided as desired to match theconfiguration of the particular machine 48. Each spiral wheel 50includes a set of spiral slots 51 extending in a general circumferentialdirection. Each of the spiral slots 51 is shaped to receive an envelopetherein by an envelope feeding device (not shown) as the spiral wheels50 rotate about their central axes.

In order to commence the stacking operation, the spiral wheels 50 arerotated in the direction of arrow A as envelopes 10 (one of which isshown in FIG. 8) are fed into the spiral slots 51 of the spiral wheels50. As the spiral wheels 50 pass through the slots 54 of the supporttable 52, the lower edge of each envelope 10 that is held in the spiralwheels 50 contacts the support table 52, thereby retracting the envelope10 out of the spiral slots 51 upon continued rotation of the spiralwheels 50. In this manner, as envelopes 10 are fed into the spiralwheels 50 at the upstream location of the support table 52, the rotatingspiral wheels 50 continuously deposit an upright stack of envelopes 10on the support table 52.

As the spiral wheels 50 continue to rotate and deposit envelopes 10, apartial stack of envelopes 30′ is created on the table 52 (FIG. 8).Thus, FIG. 8 illustrates the spiral wheels 50 as an envelope deliverymechanism. However, instead of the spiral wheels 50, various othermethods of depositing the envelopes 10 onto the support table 52 may beutilized. For example, a vacuum wheel or other similar devices may beutilized as the envelope delivery mechanism to deposit the envelopes 10on the support table 52.

The envelope stacking machine 48 includes a horizontally-extendingbacking bar 56 which is coupled to a backing bar support 58. The backingbar 56 engages the first envelope 10′ deposited on the table 52 by thespiral wheels 50 to provide support to the first envelope 10′ (andsubsequent envelopes 10 deposited on the table 52). The backing bar 56is movable in the downstream direction B (i.e., along the length of thesupport table 52) to accommodate the growing length of the partial stackof envelopes 30′. As will be discussed in greater detail below, thebacking bar 56 can be retracted (i.e., moved along its central axis)into the backing bar support 58, and FIG. 8 illustrates the backing bar56 in its extended position.

As the spiral wheels 50 continue to deposit envelopes 10 on the supporttable 52, the partial stack 30′ continues to grow and the backing bar 56moves downstream to accommodate the growing stack 30′. As can be seen inFIG. 9, eventually a full stack of envelopes 30 a is created after apredetermined number of envelopes 10 are located on the support table52.

As can be seen in FIG. 9, the machine 48 includes an upper set 58 (58 a,58 b, 58 c) of generally vertically oriented fingers and a lower set 60(60 a, 60 b, 60 c, 60 d) of generally vertically oriented fingers. Theupper set of fingers 58 includes an upstream pair of upper fingers 58 a,a downstream pair of upper fingers 58 c, and an intermediate set ofupper fingers 58 b. All of the upper fingers 58 are coupled to an upperfinger plate 62, and are configured and located to fit between the slots54 of the support table 52.

Similarly, the lower set of fingers 60 includes an upstream pair oflower fingers 60 a, a downstream pair of lower fingers 60 d, and twointermediate pairs of lower fingers 60 b, 60 c. All of the lower fingers60 are coupled to a lower finger plate 64 and are configured to fitbetween the slots 54 of the support table 52. Both the upper fingers 58and lower fingers 60 are movable in a vertical direction. In addition,as will be discussed in greater detail below, the lower fingers 60 aremovable in the upstream and downstream directions.

In the depiction of FIG. 9, the upper fingers 58 are located in theirlower or extended position, and the lower fingers 60 are shown in theirlower or retracted position. In this configuration, the upstream pair ofupper fingers 58 a engages the first envelope 10′ of the stack ofenvelopes 30 a. Once the stack of envelopes 30 a engages the upstreampair of upper fingers 58 a, the backing bar 56 can be retracted into thebacking bar support 58, as shown in FIG. 9. The upstream pair of upperfingers 58 a provides support to the stack 30 a, thereby allowingretraction of the backing bar 56 without causing collapse of the stack30 a. Next, as can be seen in FIG. 10, the backing bar 56 and backingbar support 58 move upstream to their home position adjacent to thespiral wheels 50.

As shown in FIG. 11, the backing bar 56 is then moved to its extendedposition. In this manner, the backing bar 56 creates or defines a breakbetween the stack of envelopes 30 a and a new stack of envelopes 30 bwhich will be created as the spiral wheels 50 continue to rotate andfeed new envelopes 10 onto the table 52. Thus the upper fingers 58,lower fingers 60 and backing bar 56 together form a separatingmechanism, although various other structures and devices may be utilizedas the separating mechanism.

Immediately after the backing bar 56 is moved to its extended position,the lower set of fingers 60 is raised from its lower (or retracted)position to its upper (or extended) position such that the lower set offingers 60 protrude upwardly through the slots 54 of the support table52. At the same time, the upper set of fingers 58 is raised to its upper(or retracted) position until the upper set of fingers 58 are pulled outof contact with the stack of envelopes 30 a. FIG. 11 illustrates theupper 58 and lower 60 set of fingers as they are in the process of beingmoved to their upper positions. As can be seen in FIG. 11, the upper 58and lower 60 set of fingers are configured such that the intermediatepair of lower fingers 60 b engage the front envelope 10′ of the stack ofenvelopes 30 a at the same time that the upstream upper pair of fingers58 a engage the front envelope 10′. This arrangement ensures that theenvelope stack 30 a is held in place as the upper 58 and lower 60 setsof fingers are raised.

FIG. 12 illustrates the upper set of fingers 58 in their fully retractedposition, and the lower set of fingers 60 in their fully extendedposition. In this state, the upstream pair of lower fingers 60 a (notvisible in FIG. 12) are located adjacent to the backing bar 56 (i.e.,located between the stacks 30 a, 30 b). The intermediate pair of lowerfingers 60 b engages the leading envelope 10′ of the stack of envelopes30 a to retain the stack of envelopes in place between the fingers 60 a,60 b.

As the spiral wheels 50 continue to rotate and feed envelopes 10 ontothe support table 52, the backing bar 56 and lower set of fingers 60move downstream together to accommodate the newly-created stack ofenvelopes 30 b. FIG. 13 illustrates a new stack of envelopes 30 bcreated in this manner, with the backing bar 56 and lower set of fingers60 moved downstream to accommodate this newly-created stack 30 b. Inaddition, because the first created stack of envelopes 30 a is trappedbetween the upstream lower pair of fingers 60 a and the intermediatepair of lower fingers 60 b, the first stack of envelopes 30 a issimultaneously moved downstream along the support table 52.

Next, as shown in FIG. 14, the backing bar 56 is retracted inside thebacking bar support 58 and moved to its home position. FIG. 14illustrates the backing bar 56 and backing support 58 en route to thehome position.

As shown in FIG. 15, once the backing bar 56 is returned to its homeposition, it is moved to its extended state such that the backing bar 56defines the break between the stack of envelopes 30 b and the next stackof envelopes 30 c to be created. In addition, as can be seen in FIG. 15,the upper set of fingers 58 is lowered or moved to its extended positionand the lower sets of fingers 60 is lowered or moved to its retractedpositions. The stack of envelopes 30 a is thereby held in place betweenthe upstream pair of upper fingers 58 a and the intermediate pair ofupper fingers 58 b, and the stack of envelopes 30 b is held in placebetween the backing bar 56 and the upstream pair of upper fingers 58 a.Next, the lower set of fingers 60 is moved upstream by a distance equalto the width of the stack of envelopes 30 a, 30 b (FIG. 16). Thus, theupper set of fingers 58 essentially act as a place holder while thelower set of fingers 60 are re-set.

As shown in FIG. 17, the lower set of fingers 60 are then raised ormoved to their extended positions while the upper set of fingers 58 areraised or moved to their retracted positions. The upstream pair of lowerfingers 60 a (not shown in FIG. 17) is located upstream of the stack ofenvelopes 30 b and adjacent to the backing bar 56, and the stacks ofenvelopes 30 a, 30 b are retained in place between the various sets oflower fingers 60 a, 60 b, 60 c.

Next, as shown in FIG. 18, as the spiral wheels 50 continue to rotatethe backing bar 56 and lower set of fingers 60 move downstream toaccommodate the creation of the stack of envelopes 30 c. This pattern ofretraction and movement of the backing bar 56, lowering the upper 58 andlower 60 sets of fingers, moving the lower set of fingers 60 upstream,raising the upper 58 and lower 60 set of fingers, and moving the backingbar 56 and lower fingers 60 downstream to accommodate the newest stackof envelopes 30 d is repeated until another stack of envelopes 30 d iscreated as shown in FIG. 19.

The embodiment of FIG. 19 illustrates four stacks of envelopes 30 a, 30b, 30 c, 30 d located on the support table 52. However, of course, anynumber of stacks of envelopes 30 may be created on the support table 52in the desired manner, with simple adjustments in the fingers 58, 60 andtable 52 being made to accommodate the varying number of stacks 30.

The machine 48 may include a robot arm 70 having a pair of left grippingpaddles 72 and a pair of right gripping paddles 74 to form an envelopestack moving mechanism or gripping device. The robot arm 70 is lowereduntil the left 72 and right 74 pairs of paddles are located at eitherside of the downstream-most envelope stack 30 a (FIG. 20). The left 72and right 74 paddles are then moved towards each other to compress thestack of envelopes 30 a therebetween. For example, as shown in FIG. 6,the paddles 72, 74 may compress the stack 30 a from a width W₁ to awidth W₂. The squeezing motion of the left 72 and right 74 paddles mayapply the desired compression to the stack of envelopes 30 a, andsimultaneously allows the robot arm 70 to grip the stack of envelopes 30a for movement and subsequent handling. The paddles 72, 74 and robot arm70 may be movable or controllable by various air cylinders, motor andslide combinations, linear motors and the like as is well known in theart.

Next, as shown in FIG. 21, the stack of envelopes 30 a is lifted by therobot arm 70 and moved in a direction perpendicular to the movement ofthe envelopes along the support table 52. Alternately, the stack ofenvelopes 30 a could be slid along a table surface, and could also bemoved in a direction parallel to the movement of envelopes along thesupport table 52 (not shown in FIG. 21). The compressed envelope stack30 a is then positioned on or in a banding device or bander 76 forapplication of the bands. For example, as shown in FIG. 22, the bandingdevice 76 may include a pair of banding portions 78 having a spool ofbanding material located in an associated banding spool storagecompartment 81. The spool of band material 82 is fed around the outerperimeter of a banding opening 84 of each banding portion 78.

As shown in FIG. 23, the banding portions 78 are then moved towards eachother until the outer edges of the stack of envelopes 30 a are locatedin the banding opening 84 of each banding portion 78. The bands ofbanding material 82 are then tightened down or wrapped around the outeredges of the stack of envelopes 30 a. The bands 82 are then cut andadhered to themselves to form the bands 32 around the stack of envelopes30 a to retain the envelopes 10 in the desired state of compression.

Thus, the banding device 76 wraps the bands 32 around the envelope stack30 a, cuts the bands 32 to the proper length, grips each end of the band32 and adheres, bonds or otherwise couples the ends of the bandstogether. The banding device 76 thereby mechanically or automaticallyforms the band 32 around the compressed stack, as opposed to manualapplication of the band 32. The banding device 76 may be a Zeta 144-01bander sold by Palamides GMBH of Renningen, Germany, or a B40 bandersold by Band-All Vekamo V. D. of Holland, or a US-2000 bander sold byAutomatic Taping Systems AG of Zug, Switzerland, or any of a variety ofother banding machines. The band ends 32 can be coupled together invarious manners, such as heat, ultrasonic welding, gluing or adhesive,or the like. If the banding material 82 has markings 31 located thereon,the markings may be printed during or immediately prior to the bandingprocess. Alternately, the banding material 82 may be preprinted with thedesired markings.

As indicated above, the left 72 and right 74 paddles may be utilized tocompress and grip the envelope stack 30 a. However, if desired, othermethods may be utilized to compress the envelope stack 30 a, for examplesimply compressing the envelope stack 30 a between a set of plates, orrouting the envelope stack 30 a between a pair of converging walls. Inaddition, the banding device 76 may be able to compress the stack ofenvelopes 30 a while applying the bands 32.

The banding device 76 may not necessarily apply both bands 32simultaneously. For example, a banding device 76 having only a singlebanding portion 78 may be utilized, in which case the stack of envelopes30 a or the banding device 76 can be rotated to apply a band 32 to bothends of the envelope stack 30 a. Of course, if only a single band 32 isapplied to the stack of envelopes 30 a (i.e. as shown in the embodimentof FIG. 5) then a banding device 76 with only a single banding portion78 need be utilized.

After the bands 32 are securely applied to the envelope stack 30 a, thebanding portions 78 of the banding device 76 move away from each other,as shown in FIG. 24, and the robot arm 70 lifts the banded stack ofenvelopes 30 a out of and away from the banding device 76. The robot arm70 can then place the banded stack of envelopes 30 a in a shippingcontainer, storage container, conveyor belt, or other machine or devicefor further processing. In the embodiment shown in FIG. 25, the stack ofbanded envelopes 30 a is located in a box 80 for subsequent shipping.The box 80 can be quite large, and may have a footprint that is about3′×3′ or about 4′×4′ to provide for a large storage volume. Thisfootprint is about sixteen times larger than the boxes 22 of FIG. 2A,and about eight times larger than the footprint of the boxes 26 of FIG.2B.

Although not necessarily shown in FIGS. 20-25, as the stack of envelopes30 a is banded and placed for packaging by the robot arm 70, the supporttable 52 may continue to fill with new stacks of envelopes 30 and thestacks of envelopes 30 on the table 52 can be moved downstream forsubsequent gripping and banding. The robot arm 70 then lifts thenewly-created stacks 30 away from the support table 52 for banding. Bylifting and moving the stacks of envelopes 30 away from the supporttable 52, a time buffer between the continuous flow of envelopes10/envelope packages 30 on the support table 52 and the banding process(which is an intermittent motion) is created. For example, FIG. 6schematically illustrates the package formation, compression and bandingstep. However, if desired, the banding process may be an in-line processin which bands are applied to the sets of envelopes 30 as they are fedonto the support table 52.

In addition, FIGS. 7-25 illustrate a system wherein a single robot arm70 carries the stacks of envelopes 30 to the banding device 76, and thenplaces the banded stacks 30 into a box 80. However, if desired two robotarms may be utilized. In particular, a first robot arm may lift thenewly-created stacks 30 off of the support table 52, and transport themto the banding device 76 where they are banded. The first robot arm maythen place the banded envelope stacks in a temporary storage location. Asecond robot arm or other loading device may then transport the bandedenvelope stacks from the temporary storage location into a box 80 orother storage location. This method of loading and banding (i.e. in twodiscreet steps) provides an addition time buffer and may allow forquicker processing.

Besides placing the banded envelope stacks 30 in the boxes 80, thebanded envelope stacks 30 may be placed into chipboard containers,corrugated cardboard containers, plastic shipping containers or stackingtrays. When the banded envelopes 30 are placed into large,collapsible/recyclable stacking trays, the stacking trays can then beshipped to the customers for use. Once the envelopes 10 are consumed,the stacking trays can be folded and returned to the envelopemanufacturer for reuse. In this case, the only waste (i.e., packaging)product from the customer's viewpoint is the bands 32 around eachenvelope stack 30. This provides a significant decrease in wastecompared to various boxes or other wrapping materials in which prior artenvelopes may be packaged. If desired, the boxes 80 or other storagecontainers may be located on a wheeled dolly 83 (see FIG. 25). Thewheeled dolly 83 allows the box 80 to be easily moved about the floor ofthe manufacturing or assembly plant. The boxes 80 can also be loaded inthe manner shown in FIGS. 65 and 66 and described in detail below.

FIGS. 26-33 illustrate a series of steps showing one manner in which thebanded envelope stacks 30 may be processed by a customer of the envelopestacks 30, such as a commercial envelope processor, and how the bandedstacks 30 can be utilized with envelope inserting machinery. As shown inFIG. 26, a forklift or other vehicle 100 carries a container or tray 102with a stack of banded envelopes 30 located therein. This tray 102 couldhave been loaded with envelope packages 30 in the manner shown in FIGS.24 and 25 (and/or FIGS. 65 and 66), and then shipped to the end user whowill process/stuff the envelopes. The forklift 100 positions thecontainer 102 under a robot arm 104. The robot arm 104 is movable intovarious configurations, and is slidable or translatable along anoverhead beam 106.

As shown in FIG. 27, once the forklift 100 has loaded the container 102in the appropriate location, the forklift 100 is backed away from thecontainer 102 and the robot arm 104. The robot arm 104 is then activatedand moved until it is located above an envelope stack 30′ to be lifted.Next, as shown in FIG. 28, the robot arm 104 grips and lifts theenvelope stack 30′. The robot arm 104 may have various gripping/liftingmeans for gripping and lifting the envelope stack 30′. However, in oneembodiment, the robot arm 104 includes a plurality of vacuum suctioncups located thereon (not shown) which engage the band 32 or bands 32 ofthe stack of envelopes 30′ to allow the robot arm 104 to grip and liftthe stack of envelopes 30′.

Next, as shown in FIG. 29 the stack of envelopes 30′ is positioned abovea conveyor table 108. The arm 104 then positions the stack of envelopes30′ on the conveyor table 108 and releases the stack of envelopes 30′ atthe end of the conveyor table 108, as shown in FIG. 30. The conveyortable 108 feeds the stack of envelopes 30 located thereon in adownstream direction for processing by the envelope inserting machine112. Alternately, the robot arm 104 can place envelope stacks 30 onto atray (not shown) which can hold multiple stacks 30 (i.e. three-fivestacks). This tray can then be transported, via conveyer or chain-beltsystems, to an inserting machine. The robot arm 104 may then return tothe container 102 to continue loading envelopes stacks 30 onto theconveyor table 108/tray as desired.

In many envelope inserting machines, an outer or carrier envelopereceives an inner or return envelope therein. In one embodiment of thepresent invention, the outer and inner envelopes are both packaged in(separate) banded packages. Accordingly, in FIG. 30 the outer bandedenvelopes are shown as envelope stacks 30 and the inner banded envelopesare shown as envelope stacks 110 stored within a container or tray 111.

Accordingly, the robot arm 104 may be utilized to lift a banded stack ofinner envelopes 110 (FIG. 31) out of the container 111 and to place thelifted stack of envelopes 110 on the inner envelope conveyor table 114(FIG. 32). Next, as shown in FIG. 33, an operator 120 can lift a stackof envelopes 110 off the end of the inner envelope conveyor table 114,remove the bands 32 and place the stack of envelopes 110 in or on theenvelope inserting machine 112 for further processing. The innerenvelope conveyor table 114 can then be activated to move or index thestacks of inner envelopes 110 downstream to replace the removed stack ofenvelopes 110.

The operator 120 may also move to the downstream end of the envelopeconveyor table 108 and remove envelope stacks 30 therefrom, remove thebands 32 and insert the envelope stacks 30 in or on the envelopeinserting machinery 112. The envelope conveyor table 108 can then beactivated to move the stack of envelopes 30 downstream or alternatelythe conveyor tables 108, 114 may move constantly to replenish theremoved envelope stacks. In this manner, the robot arm 104 canautomatically lift stacks of envelopes 30, 110 out of the associatedcontainers 102, 111 to constantly replenish the stack of envelopes onthe conveyor tables 108, 114.

The system of FIGS. 26-33 may be considered to be semi-automated in thatan operator removes the bands 32 and actually places the envelopes on orinto the envelope inserting machine 112. Alternately, the system ofFIGS. 26-33 may be fully automated and may not require the use of anoperator 120. In this case the conveyer tables 108, 114 may feed theirenvelope stacks directly into the envelope inserting machinery. Howeverin this scenario the bands 32 will need to be removed. Thus the bands 32could be removed by the robot arm 104, or by some other mechanism whilethe envelope stacks 30 are located on the conveyer tables 108, 114, orby the envelope inserting machine 112. Further alternately, the envelopeinserting machine 112 may include or be coupled to an envelope inputfeeding unit. The envelope input feeding unit separates and integratesindividual envelopes that were previously banded together into theenvelope inserting machine 112.

If desired, the output of the envelope inserting machine 112 (i.e. theprocessed or inserted envelopes) may also be able to be automaticallyprocessed by the robot arm 104, or by another robot arm. For example,the robot arm 104 may be able to lift the stacks of processed oroutputted envelopes and insert the processed envelopes into a shippingor storage container.

FIGS. 34-48 illustrate an automated loading process utilizing a robotarm 104 that is movable along an overhead beam 106, similar to thesystem of FIGS. 26-33. In contrast to the system of FIGS. 26-33 (whichincludes only a single envelope inserting machine 112), the system ofFIGS. 34-48 includes four envelope inserting machines 112 (see FIG. 48,although for illustrative purposes FIG. 48 does not illustrate the bandson the envelope stacks). Each envelope inserting machine 112 has twoconveyor tables that feed envelopes to be processed into the envelopeinserting machines 112. For example, one of the conveyor tables 158 mayfeed outer envelopes to an envelope inserting machine, and the otherconveyor table 126 may feed inner envelopes to be inserted into theouter envelopes (of course various other inserts, besides the innerenvelopes, can be stuffed or inserted into the outer envelopes). Asshown in FIG. 34, a forklift 100 carries a container 102 full of stacksof envelopes 30 and positions the container 102 (FIG. 35) adjacent tothe support beam 106/robot arm 104.

As shown in FIG. 36, the robot arm 104 then positions itself over thestacks of envelopes 30. As shown in FIG. 37, the robot arm 104 thenlifts four packages of envelopes 30. The robot arm 104 includes varioussuction cup devices (not shown) to lift any desired number of envelopepackages 30. Accordingly, in the embodiment illustrated in FIG. 37, therobot arm 104 includes a relatively high number of suction cups to gripand lift the four envelope packages 30.

As shown in FIG. 38, the robot arm 104 deposits one of the envelopepackages 30 on a first envelope conveyor table 126. As shown in FIG. 39,the robot arm 104 then moves along the length of the overhead beam 106towards the second conveyor table 128. The robot arm 104 then deposits astack of envelopes 30 on the second conveyor table 128 (FIG. 40). Therobot arm 104 then moves further along the overhead beam 106 until therobot arm 104 is positioned above a third conveyor table 130 (FIG. 41).As shown in FIG. 42, the robot arm 104 then deposits a stack ofenvelopes 30 onto the third conveyor table 130. As shown in FIG. 43, therobot arm 104 then moves further along the overhead beam 106 towards afourth conveyor table 132, and deposits the last held stack of envelopes30 onto the fourth conveyor table 132 (FIG. 44).

If desired the robot arm 104 may then move along the overhead beam 106to container 150 which includes additional stacks of envelopes 30located therein. The stacks of envelopes 30 in the container 150 may be,for example, inner envelopes and stacks of envelopes in the container102 may be, for example, outer envelopes. As shown in FIG. 46, the robotarm 104 can then lift the desired number of envelope stacks 30 out ofthe container 150 so that the lifted envelopes 130 may be placed in thevarious conveyor tables 152, 154, 156, 158 which receive and process theinner envelopes. As shown in FIG. 47, an operator 120 may then liftvarious stacks of envelopes 30 off of the conveyor table (i.e., conveyortable 154 in the illustrated embodiment) and load the stack of envelopes30 into or on the envelope inserting machinery 112. Of course, theoperator 120 can also load stacks of envelopes from any of the conveyortables 126, 128, 130, 132, 152, 154, 156, 158 on or into the associatedenvelope inserting machine 112. In this manner, as shown in FIG. 48, asingle robot arm 104, fed by two containers 102, 150 can constantlyreplenish the various conveyor tables 126, 128, 130, 132, 152, 154, 156,158 and the containers 102, 150 are replenished as needed by forklift.The banded nature of the envelopes 30 allows the improved processing andhandling by the robot arm 104.

The system of FIGS. 34-48, as illustrated, is a semi-automated process.However, as described above in the context of the system of FIGS. 26-33,the system of FIGS. 34-48 may be fully automated such that the conveyertables may feed their envelope stacks directly into the envelopeinserting machinery, the bands can be automatically removed, and theoutput of the envelope inserting machines can be automaticallyprocessed.

FIGS. 49-64 illustrate a fully automated envelope processing or envelopeinserting operation in which no human intervention is required duringnormal operation. For example, as shown in FIG. 49 the automated loadingprocess utilizes a robot arm 300 that is movable along an overhead beam302, similar to the system of FIGS. 26-33 and the system of FIGS. 34-48.The system of FIGS. 34-48 includes four envelope inserting machines 304,with each envelope inserting machine 304 having two conveyor tables 306,306′ that feed envelopes to be processed into the envelope insertingmachines 304 and/or receive an output (i.e., processed envelopes) fromthe envelope inserting machines 304. In particular, each envelopeinserting machine 304 includes an input conveyor table 306 upon whichunprocessed (i.e., unstuffed) envelopes are stored, and an outputconveyor table 306′ upon which processed (i.e., stuffed) envelopesoutputted by the envelope inserting machine 304 are stored. However, ifdesired each envelope inserting machine 304 may have two input tables inthe manner described and shown in FIGS. 26-48.

As shown in FIG. 49, a forklift 308 carries a container 310 full ofbanded stacks of envelopes 312 and positions the container 310 on aconveyer belt 314 located adjacent to or under the support beam302/robot arm 300. As shown in FIG. 50, the forklift 308 may then liftand remove an empty container 316 located at the opposite end of theconveyor belt 314. Next, as shown in FIG. 51, the robot arm 300positions itself over the packages of envelopes 320, 322 to be lifted,and lifts the envelope packages 320, 322 out of the associated container324. In the embodiment shown in FIG. 51, the robot arm 300 lifts twopackages of envelopes 320, 322, and may include various suction cupdevices to lift any number of desired envelope packages. For example,the robot arm 300 may be able to lift and manipulate four or more (orless) envelope packages.

As shown in FIG. 52, the bands 328 are then cut away from the envelopepackage 320, and drop down into a waste receptacle 330. The bands 328can be cut or removed by any of a variety of methods or means. Forexample, the robot arm 300 may include cutting or tearing means whichcan cut, rip, tear, sever, shear or otherwise separate the bands 328from the associated envelope package 320. Alternately, the robot arm 300may carry the gripped envelope package 320 to a separation mechanism(i.e., a blade, tearing mechanism, or the like) which can cut orotherwise remove the bands 328. Further alternately, the bands 328 maybe removed after the envelope packages 320 are deposited onto a conveyortable 306, for example, by the envelope inserting machine 304.

Next, as shown in FIG. 53, the envelope package 320 is deposited on aconveyor table 306 for an envelope inserting machine 304. Retainingmeans (not shown) may be utilized to keep the now loose stack ofenvelopes in place. As shown in FIG. 54, the robot arm 300 may then movealong its overhead beam 302 to another envelope inserting machine 304 todeposit the remaining envelope package 322 on the envelope conveyortable 306 of that envelope inserting machine 304. As shown in FIG. 55,if not already removed, the bands 328 of the remaining envelope package322 are removed and, as shown in FIG. 56, the remaining envelope package322 is deposited on the conveyor table 306 of the associated envelopeinserting machine 304. If the robot arm 300 initially picks up more thantwo envelope packages, the robot arm 300 can then move along itsoverhead beam 302 to position the remaining envelope packages onto theinput tables 306 of the other envelope inserting machines 304.

If desired, the robot arm 300 may then enter a rest state until furtheraction is required. Further action may involve returning to thecontainer 324 to lift additional packages of banded envelopes andplacing them on the input conveyor tables 306 of the envelope insertingmachines 304.

The robot arm 300 may also be utilized to process envelopes on theoutput conveyor table 306′ of the envelope inserting machines 304. Forexample, as shown in FIG. 57, the robot arm 300 may position itselfabove an output conveyor table 306′ of one of the envelope insertingmachines 304. As shown in FIG. 58, the robot arm 300 then lifts twostacks of envelopes 332 off of the output table 306′ of the envelopeinserting machine 304. Because the envelopes on the output table 306′are not banded, the robot arm 306 may be required to utilize means ormechanisms other than suction cups to lift the envelope stacks 332 offof the output conveyor tables 306′. For example, the robot arm 300 maybe able to compress a number of envelopes together or scoop a number ofenvelopes to thereby grip, lift and manipulate the envelope stack 332.Once the stacks of loose envelopes 332 are gripped and lifted (FIG. 58),the robot arm 300 may then position the gripped envelope stacks 332 overa shipping or storage box 334 (FIG. 59). The robot arm 300 may thenposition the outgoing envelopes 332 into the storage box 334 and releasethe envelope stacks 332 therein (FIG. 60).

The lifting and packaging of outgoing, stuffed envelopes may then becarried out for other ones of the envelope inserting machines 304, forexample loading envelope stacks 332′ into a box 334′ as shown in FIG.62. In this manner, the robot arm 300 can ensure that the input conveyortables 306 are constantly replenished with stacks of envelopes, and thatthe output conveyor tables 306′ are periodically unloaded to accommodateprocessed envelopes.

FIG. 63 illustrates the robot arm 300 in its home position wherein therobot arm 300 is positioned over the container 324 to grip and liftadditional packages of envelopes for positioning on the input conveyortables 306. As shown in FIG. 64, the conveyor belt 314 may be activatedto move a newly deposited container 310 downstream so that the newlydeposited container 310 can be moved into position and replace thecontainer currently being accessed 324 once the container 324 isemptied. Thus, the envelope loading and unloading process may be fullyautomated such that an operator needs only to replace the inputcontainer 324, 310 and carry away the boxes loaded with insertedenvelopes.

In this manner, it can be seen that the banded nature of the envelopestacks/packages allows for various improvements in storing, handling,and processing of the envelopes. Thus compression bound nature of theenvelopes limits warpage. In addition, the bound stacks allows aplurality of envelopes to be handled as a unit, rather than on anindividual basis. Various examples of these improvements are providedherein, although it should be understood that the envelope packages canprovide various other advantages in storing, handling, processing orotherwise which are not explicitly mentioned.

As shown in FIG. 65, the envelope packages 30 can be stacked in a rigidbox, container, or tray, such as the components 80, 102, 111, 310, 324described above. FIG. 65 illustrates a envelope packages 30 arranged ina plurality of horizontally-oriented, vertically spaced rows 350 to forma stack 354. Each row 350 includes a plurality of envelope packages 30aligned in a generally horizontal row. The envelope packages 30 of FIG.65 are arranged in a pattern wherein pairs of aligned adjacent envelopepackages 30 form envelope package pairs 352. In one embodiment, eachindividual envelope package 30 has a length that is about twice itswidth such that each envelope package pair 352 is generally square intop view. It should be noted that each envelope package 30 in anenvelope package pair 352 may not necessarily be directly coupledtogether, and may instead simply comprise two individual envelopepackages 30 placed in an aligned, side-by-side configuration.

In FIG. 65 the envelope packages 30/envelope package pairs 352 arearranged in a so-called “herringbone” pattern. Each envelope packagepair 352 in each row 350 is offset or rotated by 90 degrees from eachabutting adjacent envelope package pair 352 (i.e. each non-diagonaladjacent envelope package pair 352). In addition, the stackingarrangement in each row 350 differs from the stacking arrangement in therow 350 immediately above or below.

FIG. 65 illustrates that each envelope package pair 352 of the top row350′ is offset or rotated 90 degrees from the associated envelopepackage pair 352 located immediately therebelow in the second row 350.This arrangement helps to ensure that each envelope 10 in each envelopepackage 30/envelope package pair 352 is offset by 90 degrees from anyenvelope 10 located thereabove or therebelow. Thus, in this case,envelope packages 30 of the upper row 350′ contact and rest directly on,and have their weight fully supported by, envelope packages 30 of thesecond row 350″ immediately therebelow. It should be noted that thestacking arrangement shown in the first two rows 350′, 350″ may beextrapolated and implemented in all of the rows of 350 of the stack 354(i.e. the stack 354 may include a plurality of alternating rows 350′,350″). It should also be understood that the top row 350′ will typicallyinclude the same number of envelope packages 30/envelope package pair352 as all of the other rows 350 in the stack 354. However, in theembodiment shown in FIG. 65, portions of the top row 350′ are removed toillustrate part of the second row 350″.

This offset stacking arrangement ensures that the envelopes 10 of eachpackage 30 do not slide into the gaps between envelopes 10 of anenvelope package 30 positioned thereabove or therebelow, and therebyhelps to provide increased structural integrity to the stack 354,reduces damage to the envelopes 10 and improves ease of handling (i.e.,unpacking) the envelope packages 30. In addition, some existing envelopestacking arrangements may require separator sheets or panels to belocated between adjacent rows 350. However, the stacking arrangement ofthe present invention prevents envelopes from interleaving and thusrenders the use of separator sheets/panels unnecessary, which reducesmaterials costs and improves ease of packing and unpacking the tray 80.

The herringbone pattern of FIG. 65 illustrates one particular stackingarrangement. However, it should be understood that nearly any stackingarrangement which provides envelope packages 30/envelopes 10 that areoffset or rotated relative to envelope packages 30/envelopes 10immediately thereabove or therebelow may be utilized. For example, FIG.66 illustrates an alternate stacking arrangement wherein the envelopepackages 30 in the top row 350′ are all aligned in a first configurationor direction, and the envelope packages 30 in the second row 350″ areall aligned in a second configuration or direction that is perpendicularto the first direction. This arrangement also ensures that each envelope10 is perpendicular to any envelopes 10 located immediately thereaboveor therebelow. Of course, the stacking arrangements which can beutilized to provide this offset stacking feature are nearly limitless,and the invention is not necessarily limited to the two specificstacking arrangements shown in FIGS. 65 and 66. For example, thestacking pattern within each layer 350 can be selected in order tomaximize the number of envelope packages 30 that can be stored within agiven tray 80.

As shown in FIG. 66, the stack 354 and the tray 80 may define a gap 356therebetween, wherein the gap 356 is generally “L”-shaped and extendsalong two edges of the stack 354. In this case an inflatable air bag,bladder or bladder component 358 may be inserted into the gap. Thebladder 358 is generally “L” shaped in top view to fit into the gap 356.

In order to utilize the bladder 358, the stack 354 is first formed inthe desired configuration in a corner of the tray 80. The bladder 358 isthen inserted into the gap 356 in an uninflated or less-than-fullyinflated state. Air (or other gases/fluids, if desired) is then pumpedinto the bladder 358. As the bladder 358 inflates it expands and pressesagainst the walls of the tray 80 and the stack 354 to form a tight fitand lock the stack 354 in place. In addition, as it is inflated thebladder 358 forces air out of the envelope packages 30, thereby furthercompressing the envelope packages 30 to provide a stack 354 withincreased structural integrity which reduces damage to the envelopes 30during shipping. Further removing air also increases the strength of thestack 354 and allows it to be stacked higher, and also preventsabsorption of moisture. Once the tray 80 has been shipped to its desiredlocation, the air bladder 358 can be uninflated and removed to alloweasy access to the envelopes 10. The bladder 358 may have a refill valveor the like such that the bladder 358 can be repeatedly inflated anddeflated so that the bladder 358 can be reused.

Because the bladder 358 is located along two edges of the stack 354, thebladder 358 provides compression along two different directions of thestack 354, thereby ensuring that all envelope packages 30 arecompressed, regardless of their orientation. Of course, rather thanutilizing a single “L” shaped bladder 358, two generally rectangularbladders may be utilized and arranged in a “L” shape. In addition, ifdesired protective sheets 360 may be positioned between the bladder 358and the exposed surfaces of the stack 354 to protect the envelopes 10 ofthe stack 354. Although the bladder 358 is illustrated in conjunctionwith the stack 354 of FIG. 66, the bladder 358 may be used inconjunction with the stack 354 of FIG. 65, or any of the various otherstack arrangements.

In this manner, the improved stacking arrangement and/or air bladderimprove the stacking and shipping characteristics of the stack 354,thereby providing envelopes 10 of a more uniform shape in which damage,warping and the like is minimized. In addition, the bladder component358 can be used when storing and/or shipping a wide variety of envelopesand/or envelope packages, and is not necessarily restricted for use withcompression-bound envelope packages. Instead, the bladder component 358can be used with nearly any type of arrangement of envelopes stacked ina container.

Having described the invention in detail and by reference to thepreferred embodiments, it will be apparent that modifications andvariations thereof are possible without departing from the scope of theinvention.

1. An arrangement of envelope packages, the arrangement comprising aplurality of discreet envelope packages, each package including aplurality of generally aligned envelopes which are compressed together,wherein said plurality of envelope packages are arranged in a first rowand a second row located above said first row in a vertical directionthereof, and wherein at least one envelope package of said first row isoriented generally perpendicular to at least one envelope package ofsaid second row.
 2. The arrangement of claim 1 wherein each envelopepackage includes a plurality of gaps located between adjacent ones ofsaid envelopes of that package, and wherein the gaps of said at leastone envelope package of said first row are oriented perpendicular to thegaps of said at least one envelope package of said second row.
 3. Thearrangement of claim 2 wherein said second row is located immediatelyabove said first row such that the weight of said at least one envelopepackage of said second row is at least partially directly supported bysaid at least one envelope package of said first row, and wherein theoffset nature of said gaps generally prevents envelopes of said at leastone envelope package of said second row and said at least one envelopepackage of said first row from interleaving with each other.
 4. Thearrangement of claim 3 wherein said at least one envelope package ofsaid second row directly contacts said at least envelope package of saidfirst row.
 5. The arrangement of claim 1 wherein said first and secondrow each include a plurality of envelope packages.
 6. The arrangement ofclaim 5 wherein said first and second row each include a plurality ofenvelope packages aligned in a generally horizontal plane.
 7. Thearrangement of claim 5 wherein at least one of said row of packagesincludes at least two envelope packages which are oriented generallyperpendicular to each other.
 8. The arrangement of claim 5 wherein atleast one row of packages includes a plurality of envelope packagepairs, wherein each envelope package pair includes two generally alignedenvelope packages, and wherein any adjacent abutting envelope packagepairs are oriented perpendicular to each other.
 9. The arrangement ofclaim 5 wherein both rows of packages includes a plurality of envelopepackage pairs, wherein each envelope package pair includes two generallyaligned envelope packages, and wherein both rows are configured suchthat any adjacent abutting envelope package pairs are orientedperpendicular to each other.
 10. The arrangement of claim 9 wherein saidfirst and second rows are arranged such that each envelope package pairof said first row is oriented perpendicular to an envelope package pairof said second row located immediately thereabove.
 11. The arrangementof claim 9 wherein each envelope package has a length that is abouttwice as long as a width thereof.
 12. The arrangement of claim 5 whereinsaid first and second rows of packages are configured such that all ofsaid envelope packages of each row are aligned with each other.
 13. Thearrangement of claim 1 further comprising a plurality of alternatingvertically spaced first and second rows, and wherein at least oneenvelope package in each first row is oriented generally perpendicularto at least one envelope package in each second row.
 14. The arrangementof claim 1 wherein each envelope package includes a band extendingaround said plurality of compressed envelopes and retaining theassociated envelopes in a state of compression.
 15. The arrangement ofclaim 14 wherein said band is made of a generally non-elastic material.16. An arrangement of envelope packages, the arrangement comprisingfirst and second discreet envelope packages, each package including aplurality of generally aligned envelopes which are compressed togetherand having a plurality of gaps formed between adjacent ones of saidenvelopes, wherein second envelope package is located vertically aboveand directly contacting and supported by said first envelope package,and wherein said first and second envelope packages are orientedgenerally perpendicular to each other such that the gaps of said firstand second envelope packages are generally perpendicular to generallyprevent envelopes of said at first and second envelope packages frominterleaving into each other.
 17. A method for arranging envelopescomprising: providing a container; placing a plurality of envelopepackages in said container in an arrangement, the arrangement comprisingfirst and second discreet envelope packages, each package including aplurality of generally aligned envelopes which are compressed togetherand having a plurality of gaps formed between adjacent ones of saidenvelopes, wherein second envelope package is located vertically aboveand directly contacting and supported by said first envelope package,and wherein said first and second envelope packages are orientedgenerally perpendicular to each other such that the gaps of said firstand second envelope packages are generally perpendicular to generallyprevent envelopes of said at first and second envelope packages frominterleaving into each other.
 18. An envelope packaging arrangementcomprising: a storage container; an envelope stack including a pluralityof envelopes located in said storage container; and an inflatable anddeflatable bladder component located in said storage container, whereinsaid bladder component compresses said plurality of envelopes of saidenvelope stack together to improve the shipping characteristics of saidenvelope stack.
 19. The packaging arrangement of claim 18 wherein saidplurality of envelopes are in the form of a plurality of discreetenvelope packages, each package including a plurality of generallyaligned envelopes and a band extending around said plurality ofgenerally aligned envelopes and retaining said envelopes in a state ofcompression.
 20. The packaging arrangement of claim 19 wherein saidplurality of envelope packages are arranged in a first row and a secondrow located above said first row in a vertical direction thereof, andwherein at least one envelope package in said first row is orientedgenerally perpendicular to at least one envelope package in said secondrow.
 21. The packaging arrangement of claim 20 wherein each envelopepackage includes a plurality of gaps located between adjacent ones ofsaid envelopes of that package, and wherein the gaps of said at leastone envelope package of said first row are oriented perpendicular to thegaps of said at least one envelope package of said second row, andwherein said second row is located immediately above said first row suchthat said at least one envelope package of said second row is in directcontact with said at least one envelope package of said first row, andwherein the offset nature of said gaps generally prevents envelopes ofsaid at least one envelope package of said second row and said at leastone envelope package of said first row from interleaving with eachother.
 22. The packaging arrangement of claim 18 wherein said bladderarrangement extends significantly along at least two edges of saidenvelope stack such that said bladder arrangement compresses saidplurality of envelopes of said envelope stack together in at least twodifferent directions.
 23. The packaging arrangement of claim 18 whereinsaid container is generally rectangular in top view, and wherein saidenvelope stack is positioned in a corner of said container and defines agenerally “L”-shaped gap between said envelope stack and said container,and wherein said bladder arrangement is generally “L” shaped in top viewand configured to closely fit into said gap when inflated.
 24. Thepackaging arrangement of claim 23 wherein said bladder arrangement isconfigured to be repeatedly inflated and deflated such that said bladderarrangement can be reused.
 25. A method for handling envelopescomprising: providing a storage container; forming a stack of envelopesin said container; after said forming step, positioning a bladdercomponent in said container; and after said positioning step, inflatingsaid bladder component such that bladder component compresses saidenvelope stack together to improve the shipping characteristics of saidenvelope stack.
 26. The method of claim 25 further comprising the stepsof receiving said storage container, deflating said bladder and removingenvelopes from said stack of envelopes from said container.